JP2006223011A - Manufacturing method for molded motor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method capable of enhancing the dimensional precision of a molded motor, and capable of reducing the vibration and noise of the molded motor. <P>SOLUTION: When the molded motor is formed, a part for forming a bearing housing of a mold is made into a movable mold 13. Before a mold material is pressurized and charged into the mold, the movable mold is fixed at a position where the bearing housing is not formed. After the mold material is pressurized and charged into the mold, the movable mold is moved to the position where the bearing housing is formed so as to perform molding. Thus, the enhancement of the dimensional precision of the molded motor and reductions in the vibration and the noise of the molded motor can be attained. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a molded motor that is used in a washing machine, an air conditioner, a pump unit, a water heater, and the like and that is required to be quiet.

  2. Description of the Related Art Conventionally, a stator of a motor has been widely adopted in which the entire stator is molded with a molding material because of its vibration-proof property, shape flexibility and reliability. Further, the bearing housing into which the bearing is inserted and fixed is also integrally formed of a molding material in order to improve work efficiency. The typical structure will be described with reference to FIG. FIG. 1 shows a motor. As shown in FIG. 1, the motor comprises a stator core 5, a stator winding 4, a stator core 5, and a mold material 6 molding the stator winding 4, and the stator is fixed. A rotor 3 to which a rotor shaft 7 is fixed is attached to a stator frame attached to a child through a bearing housing 1 and a metal bracket 2 which are formed integrally with the stator by a molding material. It has been.

  Further, a mold manufacturing method of a mold motor that has been conventionally used will be described with reference to FIG. FIG. 2 is a schematic view showing a mold. The stator core 5 with the stator winding 4 applied is installed in the lower mold 10, and the space formed by fixing the upper mold 9 and the lower mold 10 is pressure-filled from the gate 12 with the molding material, The stator of the mold motor is formed. At this time, the bearing housing 1 into which the bearing is inserted and fixed is formed by a lower-type bearing housing forming portion 11.

In addition, conventionally used molding materials are thermoplastic resins such as polyethylene terephthalate, polybutylene terephthalate, polyamide, PPS, ABS, etc., and thermosetting resins such as unsaturated polyester molding materials, phenol, and epoxy resins. is there.
JP 09-174616 A

  In the conventional molded motor as described above, the gap accuracy between the rotor and the stator cannot be improved due to the size of the bearing housing and the accuracy of roundness. There is a strong demand for further reductions in noise and vibration.

  This invention is invented in view of such a subject, and it aims at providing the manufacturing method of a molded motor with little noise and vibration.

In order to solve this problem, the present invention provides a mold in which a winding is formed on a main magnetic path portion of a stator iron core such as a yoke or a tooth, and a bearing housing is also formed of a mold material at the same time as the molding is integrally performed with the mold material. In the motor manufacturing method, the part of the mold that forms the bearing housing is a movable mold part, and the movable mold part is fixed at a position where the bearing housing part is not formed before the mold material is pressurized and filled in the mold. The mold motor is manufactured by moving to the position where the bearing housing portion is formed immediately after the mold material is pressure-filled in the mold.
According to the present invention, noise and vibration generated while the mold motor is rotating are reduced.

  As described above, according to the first aspect of the present invention, it is possible to improve the dimensions of the bearing housing and the accuracy of roundness, and to obtain the effect of reducing the occurrence of horsesound and vibration of the molded motor.

  In addition, the molded motor manufactured from the unsaturated polyester molding material according to claim 2 or claim 8 can achieve the effect of reducing noise and vibration of the molded motor without impairing the workability during molding.

  In addition, the molded motor produced by the molding method according to claim 3 can obtain the effect of reducing the generation of noise and vibration of the molded motor without impairing the workability when molding the molded motor.

  Moreover, according to the invention of Claim 4, a washing machine with low noise and vibration can be provided.

  Moreover, according to the invention of Claim 5, an air conditioner with low noise and vibration can be provided.

  Further, according to the invention described in claim 6, a pump unit with low noise and vibration can be provided.

  Further, according to the seventh aspect of the present invention, a water heater with low noise and vibration can be provided. Conversion

  According to the first aspect of the present invention, a winding is applied to a main magnetic path portion of a stator iron core such as a yoke or a tooth, and a bearing housing is also formed of a molding material at the same time as the molding is integrally performed with the molding material. In the mold motor manufacturing method, a part of the mold that forms the bearing housing is a movable mold part, and the movable mold part is located at a position where the bearing housing part is not formed before the mold material is pressurized and filled in the mold. By moving to the position where the bearing housing part is formed immediately after the mold material is pressed and filled in the mold and manufacturing the mold motor, the dimensions of the bearing housing and the accuracy of roundness are improved. By improving the gap accuracy between the rotor and stator, noise and vibration generated during motor rotation can be reduced. There is.

  The invention according to claim 2 of the present invention is that, in claim 1, the molding material is an unsaturated polyester molding material, and the curing start time at 145 ° C. is 3 seconds to 120 seconds. By adjusting the saturated polyester molding material, it is possible to smoothly move the movable part that forms the bearing housing of the mold, and the noise and vibration generated while the mold motor is rotating without impairing the workability during molding. There is an effect that can be reduced.

  The above temperature of 145 ° C is any one of 145 ° C ± 0.5 ° C, 145 ° C ± 1 ° C, 145 ° C ± 2 ° C, 145 ° C ± 3 ° C, 145 ° C ± 4 ° C, 145 ° C ± 5 ° C. It is possible even in the range.

  Unsaturated polyester molding materials are excellent in reliability such as heat resistance and moisture resistance, and are suitable for the present invention because the adjustment of the curing start time after being pressure-filled in the mold can be arbitrarily adjusted.

  When the curing start time at 145 ° C is less than 3 seconds, it is difficult to smoothly move the movable part that forms the bearing housing of the mold after pressurizing and filling the unsaturated polyester molding material into the mold. Take. Further, when the curing start time at 145 ° C. is 120 seconds or more, the working time cannot be shortened, and a smooth molding operation becomes difficult.

  According to a third aspect of the present invention, the movement of the movable mold part forming the bearing housing according to the first aspect is performed before the unsaturated polyester molding material pressure-filled in the mold starts to harden. The molding motor is moved to the position where the housing part is formed, and the molded motor produced by this molding method can reduce the noise and vibration of the molded motor without impairing the workability when molding the molded motor. There is an effect that.

  When the movable mold part that forms the bearing housing is moved after the unsaturated polyester molding material that is pressure-filled in the mold starts to harden, smooth movement cannot be achieved and dimensional accuracy compared to conventional methods. Cause the deterioration.

  According to a fourth aspect of the present invention, there is provided a washing machine equipped with the molded motor according to any one of the first to third aspects, wherein the washing machine has low noise and vibration.

  According to a fifth aspect of the present invention, there is provided an air conditioner equipped with the molded motor according to any one of the first to third aspects, wherein the air conditioner has low noise and vibration.

  According to a sixth aspect of the present invention, there is provided a pump unit equipped with the molded motor according to any one of the first to third aspects, wherein the pump unit has low noise and vibration.

The investigation according to the seventh aspect of the present invention provides a water heater equipped with the molded motor according to any one of the first to third aspects and having a low noise and vibration.

  An example of the present invention will be described below with reference to FIG. FIG. 3 is a schematic view of a mold used in the present invention. When compared with the mold of the conventional mold motor shown in FIG. 2, the bearing housing forming portion 11 is replaced with the bearing housing forming movable portion 13. It has been improved. Next, the manufacturing procedure of the molded motor prepared in the embodiment of the present study will be described.

  First, the diameter of the bearing housing forming movable portion 13 was adjusted to about 20 mm so that the bearing housing had a diameter of 20 mm. Next, the unsaturated polyester molding material to be used is an unsaturated polyester resin comprising a 40 to 60 wt% styrene solution of an isofuric acid-based unsaturated polyester alkyd. Owt%, 7.5% by weight of a low-shrinkage agent composed of a styrene solution of 40 to 70% by weight of polystyrene resin, 0.3% by weight of t-butyl pentene zeoate as a radical polymerization initiator, 10% by weight of glass fiber of reinforcing agent, internal separation Zinc stearate 1.5 wt% as a mold and aluminum hydroxide 64.7 wt% as other fillers were kneaded with a kneader to obtain an unsaturated polyester resin molding material.

  Next, the upper die and the lower die are temperature-controlled at 145 ° C., and the stator iron core 5 provided with the stator winding 4 to be molded is preheated to 80 ° C. Next, the preheated stator iron core is installed in the lower mold, the upper mold is fixed to the lower mold, and the unsaturated polyester molding material is pressurized and filled into the mold from the gate 12. At this time, the bearing housing forming movable portion 13 is in a position where the bearing housing portion is not formed.

  The unsaturated polyester molding material is pressure-filled in the mold, and before the unsaturated polyester molding material begins to cure, the bearing housing forming movable portion 13 is moved to a position where the bearing housing is formed, and the unsaturated polyester molding is performed. After the material has been cured, the molded stator is removed from the mold. Next, it was cooled to room temperature, and the dimensions, roundness, and cylindricity of the bearing housing were measured. Each standard deviation was also calculated. The number of units measured is 10. Further, as a comparative example, a molded motor manufactured by a manufacturing method that does not move a bearing housing forming portion as shown in FIG. The results are shown in Table 1.

From the results, compared to the comparative example, the present invention example can improve the dimensional accuracy of the bearing housing, can also improve the gap accuracy between the rotor and the stator, and reduce the noise and vibration generated during the rotation of the molded motor. I was able to.

  Further, the present study can be applied to a portion where a bracket or the like is inserted other than the bearing housing.

  As described above, according to the method for manufacturing a molded motor of the present invention, the dimensional accuracy of the bearing housing can be improved, the gap accuracy between the rotor and the stator can be improved, and noise and vibration generated during the rotation of the molded motor can be reduced. Can be reduced.

  The method for manufacturing a molded motor of the present invention is optimal for reducing the noise and vibration of the molded motor, and is useful for applications in which vibration and noise are hated.

Explanatory drawing showing the configuration of the mold motor Schematic diagram of conventionally used molds Schematic of mold in Example 1 of the present invention

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Bearing housing 2 Bracket 3 Rotor 4 Stator winding 5 Stator iron core 6 Mold material 7 Rotor shaft 8 Bearing 9 Upper mold 10 Lower mold 11 Bearing housing forming part 12 Gate 13 Bearing housing forming movable part

Claims (8)

In a method of manufacturing a molded motor, in which a winding is applied to a main magnetic path portion of a stator iron core such as a yoke or a tooth, and a bearing housing is also formed of the molding material at the same time as molding with the molding material. The movable mold part is fixed to a position where the bearing housing part is not formed before pressurizing and filling the mold material with the mold material, and the mold material is pressurized in the mold. A method for manufacturing a molded motor, comprising: moving to a position where a bearing housing portion is formed immediately after being filled. The method for manufacturing a molded motor according to claim 1, wherein the molding material is an unsaturated polyester molding material, and the curing start time at 145 ° C is 3 seconds to 120 seconds. The movable mold part forming the bearing housing is moved to a position where the bearing housing part is formed before the unsaturated polyester molding material pressure-filled in the mold starts to cure. A method for producing a molded motor according to 1. A washing machine equipped with a motor manufactured by the manufacturing method according to any one of claims 1 to 3. An air conditioner equipped with a motor manufactured by the manufacturing method according to any one of claims 1 to 3. The pump unit carrying the motor manufactured by the manufacturing method in any one of Claims 1-3. A water heater equipped with a motor manufactured by the manufacturing method according to any one of claims 1 to 3. The method for manufacturing a molded motor according to claim 2, wherein the temperature 145 ° C is in the range of 145 ° C ± 0.5 ° C, 145 ° C ± 2 ° C, 145 ° C ± 5 ° C.